Check out Jaymar made in Canada very nice product. I have sold it for years. every piece they will do in microfiber or leather.

You're right when you say custom sectionals are hard to find, especially with a sleeper sofa option. I found and eventually purchased a sectional like the one you describe above from clubfurniture.com. They have a variety of fabric, leather and slipcovered corner wedge sectionals that can be built to fit your room dimensions. I've included a link below to their sectionals page. Good luck!

Here is a link that might be useful: Large Sectional Sofas With Sleeper Sofa Option

I had checked out their website already and it sounds good. I just want to make sure that it's a quality product and not one of those "you get what you pay for" things. Have you gotten your sofa yet and are you happy with it? What about the quality of the fabric and the feel of the cushions? I want a sofa that is pretty cushy and I was going to upgrade to the down option. Please let me know your impressions - it would be really helpful. I was also researching a sofa from Carolinachair.com. They seem to have a little bit better quality and better fabric choices, but the sofa I want is also about $2,000 more and I don't know that it's worth spending the extra money. Any input is appreciated.

I've been looking at Sherrill recently - I know they have sleepers and sectionals - don't know if they have a combo or what you need - but you could do a dealer locator search at their website and call.

bsacks I'm thinking of purchasing a sectional from carolinachair. Did you purchase yours from them? Are you happy with your sofa?